Hi-Rel HOLD-UP MODULE
HUGD-50 : 50W POWER
• Unique Product for Hold-Up Solution
• Reduce Capacitance by 80%
• High efficiency (98%)
• Power range : from 4W to 50W
• Compatible with 9-36 or 16-40VDC Converter
• Include monitoring signals
• Programmable inrush current limitation
Gaia Converter FC97-027.01/06 Revision H
©
REDEFINING THE SOURCE OF POWER
1-General
Hi-Rel
Grade
For locations, phone, fax, E-Mail see back cover
2-Product Selection
The GAIA Converter Hold up device
HUGD-50 provides a state-of-the-art solution to
the problem of maintaining electronic system in
operation during input bus drop-out with enough
time. Usually this approach uses very large
capacitors because they are only charged at the
voltage at which power fail. The Gaïa Converter
HUGD-50 module provides an alternative solu-
tion to reduce the amount of capacitance needed
by charging the hold up capacitor at a high vol-
tage (typically 38V) while limiting the input
current.
The HUGD-50 needs to be connected between
the line source and DC/DC modules (if an EMI
filter and /or a pre-regulator are used, the
HUGD-50 is connected between them and the
converters). Basically the HUGD-50 charges the
external capacitor to 38V while powering the
DC/DC converters. If the power fails, the
HUGD-50 generates a signal and the converters
are powered from the external capacitor. The
HUGD-50 can be used either with 16-40V or 9-
36V input voltage DC/DC converters since the
«power fail voltage» is externally adjustable
between 8.8V and 15.3V by the user.
The HUGD-50 features 3 modes of operations:
• Charging operation mode : when the
input voltage ramps-up and reaches the start-
up charge threshold (which is set at 1Vdc above
the «power fail voltage»), the HUGD-50 begins
to charge the external capacitor at 38 VDC while
powering the dc/dc converter. the charging
current is controled and externally adjustable
between 100mA and 2A by a resistance. The
capacitor charging time depends on the charging
current. When the capacitor voltage reaches 34V,
(representing 90% of charge) the signal (active,
floating output collector) «capacitor charged»
is activated and the HUGD-50 enters in the nor-
mal operation mode.
• Normal operation mode : in normal
operation mode with the capacitor charged and
the input bus is between the «output power fail»
and 40VDC, the HUGD-50 consumes only power
to keep the capacitor charged (i.e.less than 1W.
The voltage drop between input and output is
lower than 150mV in the worth case (50W power
and 9 VDC input voltage) The HUGD-50 will
operate indefinitely until the input voltage drops
below the «power fail voltage» threshold.
• Power fail mode : when the input vol-
tage drops below the «power fail voltage»
threshold a «power fail» signal is activated and
the HUGD-50 disconnects input and output and
connects the hold-up capacitor to the output.
At this point the DC/DC converters are powered
by the capacitor. When 90% of the usable stored
energy in the capacitor is activated and operation
will stop as the energy reaches zero.
4
Hold-Up Solution
16-40V & 9-36V DC/DC Converter Compatible
Metallic Case
(/T) : option for -55°C start up operating temperature.
(/S) : option for screening and serialization
HUGD - 50 (/T) and/or (/S)
For locations, phone, fax, E-Mail see back cover
2
Hi-Rel
Grade
HUGD-50 Series
Gaia Converter FC97-027.01/06 Revision H
©
4
3- Block Diagram
The HUGD-50 module includes 3 main circuits :
• An input monitoring circuit
• An hold-up charger circuit
• A hold-up monitoring circuit
• Input monitoring Circuit :
The input monitoring circuit monitors the value of
the input bus voltage and compares it to the power
fail threshold voltage (Vth) set externally through a
resistor. Depending on this comparison, the circuit
allows the activation of the hold-up switch and the
hold-up charger and generates an isolated power fail
flag (PF).
• Hold-up Charger :
The hold-up charger is used to feed the hold-up
capacitor with a constant Vc=38V voltage. The de-
sign of this charger has been optimized to minimize
the input inrush current which can be set externally
through the Vcl input by a resistor.
• Hold-up monitoring Circuit :
The hold-up monitoring circuit monitors the charging
status of the hold-up capacitor.
The circuit generates 2 isolated flags : the capacitor
charged flag (CC) and the capacitor discharged flag
(CD).
These flags can be used at system level for manage-
ment of power interruption (VME system, PCI, ...)
The HUGD-50 features 3 modes of operations :
• Charging operation mode
• Normal operation mode
• power fail mode
The following figure represents the HUGD-50 series
block diagram.
HUGD-50 Block Diagram
Input
Monitoring
Hold-up
Monitoring
Vi
Vcl
Vth
Vo
Hold-up
Charger
Gi Go
Vc
CC
CD
PF
For locations, phone, fax, E-Mail see back cover
3
Hi-Rel
Grade
HUGD-50 Series
Gaia Converter FC97-027.01/06 Revision H
©
4
4- Electrical Specifications
Data are valid at +25°C, unless otherwise specified.
Parameter Conditions Limit or typical Units HUGD-50
Input
Permanent input voltage
range (Ui)
Full temperature load
Full load
Minimum
Maximum
VDC
VDC
9
40
Transient input voltage Full temperature load
Full load Maximum VDC/ms 50/100
Power fail voltage
threshold (Vfail)
with the setting
Vth unconnected
Minimum
Typical
Maximum
VDC
VDC
VDC
15
15,3
15,6
Power fail voltage
threshold (Vfail)
with the setting
Vth connected to ground
Minimum
Typical
Maximum
VDC
VDC
VDC
8,6
8,8
9
Input current consumption
during charging at 28V
min: Vcl unconnected
max: Vcl connected to ground
Minimum
Maximum
A
A
0,1
1,5
Input current consumption
during charging at 16V
min: Vcl unconnected
max: Vcl connected to ground
Minimum
Maximum
A
A
0,1
2,2
Output
Output admissible power Full temperature load
Full load Maximum W50
Dissipated power Vin @ 9V, full power Maximum W1
Voltage drop input/ouput Vin @ 9V, full power Maximum mV 160
Capacitor charged signal
threshold
Minimum
Maximum
VDC
VDC
33,8
34,8
Capacitor discharged signal
threshold
with setting
Vth unconnected
Minimum
Maximum
VDC
VDC
15,9
16,7
Capacitor discharged signal
threshold
with setting
Vth connected to ground
Minimum
Maximum
VDC
VDC
9,4
10,2
Maximum admissible
hold-up capacitor
Minimum
Maximum
µF
µF
470
30.000
Hold-up time at full load Vth unconnected
Vth connected to ground
Minimum
Minimum
µs/µF
µs/µF
11,2
12,8
Hold-up time at 10W load Vth unconnected
Vth connected to ground
Minimum
Minimum
µs/µF
µs/µF
55,6
64,4
For locations, phone, fax, E-Mail see back cover
4
Hi-Rel
Grade
HUGD-50 Series
Gaia Converter FC97-027.01/06 Revision H
©
4
5- Switching Frequency
7- Reliability Data
Parameter Conditions Limit or typical Specifications
Switching frequency
Full temperature range
Ui min. to max.
No load to full load
Nominal, fixed 200 KHz
6- Isolation
Characteristics Conditions Temperature Specifications
Mean Time Between Failure (MTBF)
According to MIL-HDBK-217F
Ground fixed (Gf) Case at 40°C
Case at 85°C
1.500.000 Hrs
590.000 Hrs
Airborne, Inhabited,
Cargo (AIC)
Case at 40°C
Case at 85°C
730.000 Hrs
300.000 Hrs
Mean Time Between Failure (MTBF)
According to IEC-62380-TR Avionics Military Cargo /Consult factory
Parameter Conditions Limit or typical Specifications
Electric strength test voltage Input to output / No isolation
For locations, phone, fax, E-Mail see back cover
5
Hi-Rel
Grade
HUGD-50 Series
Gaia Converter FC97-027.01/06 Revision H
©
4
8- Thermal Characteristics
Characteristics Conditions Limit or typical Performances
Operating ambient temperature
range at full load Ambient temperature * Minimum
Maximum
- 40°C
+ 85°C
Operating case temperature
range at full load Case temperature Minimum
Maximum
- 40°C
+105°C
Storage temperature range Non functionning Minimum
Maximum
- 55°C
+ 125°C
Thermal resistance Rth case to ambient in free air
natural convection Typical 12°C /W
Note * : The upper temperature range depends on configuration, the user must assure a max. case temperature of + 105°C.
10 10030 110807060 9020 40 50
25%
75%
50%
100%
Power (W)
Temperature (˚C)
Full load ambient temperature without derating : 85˚C
Maximum case temperature : 105˚C
Natural convection operation area
Additionnal cooling operation area
Maximum storage temperature : 125˚C
The HUGD-50 series operating case temperature must not exceed 105°C. The maximum ambient temperature admissible for
the DC/DC converter corresponding to the maximum operating case temperature of 105°C depends on the ambient airflow,
the mounting/orientation, the cooling features and the power dissipated.
To calculate a maximum admissible ambient temperature the following method can be used. Knowing the maximum case
temparature Tcase = 105°C of the module, the power used Pout and the efficiency η :
• determine the power dissipated by the module Pdiss that should be evacuated :
Pdiss = Pout(1/ηη
ηη
η - 1)
• determine the maximum ambient temperature :
Ta = 105°C - Rth x Pdiss
where Rth is the thermal resistance from the case to ambient.
The previous thermal calculation shows two areas of operation :
• a normal operation area in a free natural ambient convection (grey area in this following graph),
• an area with cooling features (air flow or heatsink) ensuring a maximum case temperature below the maximum
operating case temperature of 105°C (white area in the following graph).
For locations, phone, fax, E-Mail see back cover
6
Hi-Rel
Grade
HUGD-50 Series
Gaia Converter FC97-027.01/06 Revision H
©
4
9- Environmental Qualifications
The modules have been subjected to the following environmental qualifications.
Characteristics Conditions Severity Test procedure
Climatic Qualifications
Life at high
temperature
Duration
Temperature / status of unit
Test D : 1.000 Hrs
@ 105°C case, unit operating
@ 125°C ambient, unit not operating
MIL-STD-202G
Method 108A
Altitude
Altitude level C
Duration
Climb up
Stabilization
Status of unit
40.000 ft@-55°C
30 min.
1.000 ft/min to 70.000 f@-55°C,
30 min.
unit operating
MIL-STD-810E
Method 500.3
Humidity cyclic
Number of cycle
Cycle duration
Relative humidity variation
Temperature variation
Status of unit
10
Cycle I : 24 Hrs
60 % to 88 %
31°C to 41°C
unit not operating
MIL-STD-810E
Method 507.3
Humidity steady
Damp heat
Temperature
Duration
Status of unit
93 % relative humidity
40°C
56 days
unit not operating
MIL-STD-202G
Method 103B
Salt atmosphere
Temperature
Concentration NaCl
Duration
Status of unit
35°C
5 %
48 Hrs
unit not operating
MIL-STD-810E
Method 509.3
Temperature
cycling
Number of cycles
Temperature change
Transfert time
Steady state time
Status of unit
200
-40°C / +85°C
40 min.
20 min.
unit operating
MIL-STD-202A
Method 102A
Temperature shock
Number of shocks
Temperature change
Transfert time
Steady state time
Status of unit
100
-55°C / +105°C
10 sec.
20 min.
unit not operating
MIL-STD-202G
Method 107G
Mechanical Qualifications
Vibration
(Sinusoidal)
Number of cycles
Frequency / amplitude
Frequency / acceleration
Duration
Status of unit
10 cycles in each axis
10 to 60 Hz / 0.7 mm
60 to 2000 Hz / 10 g
2h 30 min. per axis
unit not operating
MIL-STD-810D
Method 514.3
Shock
(Half sinus)
Number of shocks
Peak acceleration
Duration
Shock form
Status of unit
3 shocks in each axis
100 g
6 ms
1/2 sinusoidal
unit not operating
MIL-STD-810D
Method 516.3
Bump
(Half sinus)
Number of bumps
Peak acceleration
Duration
Status of unit
2000 Bumps in each axis
40 g
6 ms
unit not operating
MIL-STD-810D
Method 516.3
For locations, phone, fax, E-Mail see back cover
7
Hi-Rel
Grade
HUGD-50 Series
Gaia Converter FC97-027.01/06 Revision H
©
4
10- Application Notes
10-1 General on Input Bus Shut-
Down Requirements
During bus power drop-out, avionics and military
systems require a maintain of operation for saving
data and controlling the shut-down.
10-1-1 Capacitor Stand-Alone Solution
To maintain operation during this power drop-out, the
traditional approach is the use of a bulk capacitor
connected at the input of the converters to power
them when power drops-out. The capacitor needed
depends on the system specifications, the load and
the efficiency of the DC/DC converters and the amount
of capacitor for a given hold-up time. The value of the
capacitance is determined by the following formula :
where :
C : is the required capacitor (in farads)
P : is the power at the load (output of converter)
(in watts)
h : is the efficiency of the converter at rated load
Dt : is the required hold up time (in seconds)
V1 : is the initial charged capacitor voltage (in volts)
V2 : is the low line voltage of DC/DC converter
For a typical hold-up time of 50 ms with 50W power
(at the input of the DC/DC converter with 80%
efficiency) plugged on a MIL-STD-704D 28V bus that
can range down to 22V and considering the minimum
permanent input voltage of GAIA Converter module at
16V, the required capacitance is a huge with value of
18.000 µF/40V rated.
The duration of this shut-down operation is defined in
different standards and can last up to 7 secondes.
10-1-2 Capacitor with Hold Up Module Solution
To reduce drastically the size of this capacitor, GAIA Converter
proposes the hold up module HUGD-50 that will charge the
capacitor at a much higher voltage (typically 38V).
Moroever this module allows a selection of the minimum
threshold voltage at which the capacitance will begin to
power the converters. In this case the amount of capacitance
needed for a given hold up time is determined by the following
formula :
where :
C : is the required capacitor (in farads)
P : is the power to the load (output of converter) (in watts)
h : is the efficiency of the converter at rated load
Dt : is the required hold up time (in seconds)
V2 : is the low line voltage of DC/DC converter (in volts).
For a typical hold-up time of 50 ms with 50W power (at the
input of the DC/DC converter with 80% efficiency) plugged
on a MIL-STD-704D 28V bus and using the hold up module
the capacitance required will decrease down to value of
5.000 µF/40V rated.
2 x P x (Dt + 0.01)
{ h x ( 382 - V22 )}
C2 =
( 2 x P x Dt )
{ h x ( V12 - V22 )}
C1 =
For locations, phone, fax, E-Mail see back cover
8
Hi-Rel
Grade
HUGD-50 Series
Gaia Converter FC97-027.01/06 Revision H
©
4
10- Application Notes (continued)
0
100
200
300
400
500
600
700
800
900
1000
0 5 000 10 000 15 000 20 000 25 000 30 000
Hold-up capacitance (µ
µµ
µF)
Hold-up time (ms)
50W
40W
30W
20W
The external capacitor supplies the energy for the DC/DC converters operation during failure.
The capacitance should not exceed 30.000µF, and should be higher than 470µF.
The amount of capacitance for a given hold up time is given by the formula :
2 x P (Dt + 0.01 )
382 -VL
2
C =
where
C: is the required capacitance (in Farads)
P: is the power consumed by the DC/DC converters (in Watts)
Dt : is the required hold-up time (in seconds)
VL: is the lower admissible voltage of DC/DC converters (in volts)
The following curve gives the capacitor value as a function of the required hold up time. Gaia Converter recommends a high
CV low ESR and extended temperature capacitor.
10-2 Hold-up Capacitor Selection with HUGD-50 Solution
For locations, phone, fax, E-Mail see back cover
9
Hi-Rel
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HUGD-50 Series
Gaia Converter FC97-027.01/06 Revision H
©
4
10- Application Notes (continued)
The «power fail voltage» threshold determines the operation
mode of the HUGD-50.
This threshold has to be set up in conjunction with the
type of modules used (i.e. 9-36 VDC or 16-40 VDC input
voltage type of modules) and can be adjusted between
8,8VDC and 15,3VDC by external resistance Rth connected
between the Vth pin and Gout pin.
The HUGD-50 controls the inrush current (charging current)
to remain between 100 mA to 2A by an external resistance
Rcl connected between the Vcl pin and the Gout pin. This
charging current is a direct function of the charging time
0
100
200
300
400
500
600
700
800
900
0 500 1000 1500 2000 2500
Rcl
Charging rate in µs/µF
Vi=16V
Vi=28V
Vi=40V
Vth unconnected will set up the threshold at 15,3VDC valid
for 16-40Vdc input modules, Vth connected to ground will
set up the threshold at 8,8VDC valid for 9-36Vdc input
modules.
If the HUGD-50 is used with the PGDS-50-N-K, Vth has to
remain unconnected; with the PGDS-50-O-K, Vth has to be
connected to Go. The following curve determines the
function of Vth threshold as a function of the resitor Rth.
knowing that the capacitor is charged at 38VDC. The
following curve gives the resistance Rcl value as a function
of current & charging time.
10-4 Charging Current Setting : VCL
10-3 Power Fail Voltage Threshold : Vth
1,00E+00 1,00E+01 1,00E+02 1,00E+03 1,00E+04 1,00E+05 1,00E+06
8,5
9
9,5
10
10,5
11
11,5
12
12,5
13
13,5
14
14,5
15
15,5
Power fail voltage threshold versus Rth
Rth (ohms)
Power fil voltage threshold (Vdc)
For locations, phone, fax, E-Mail see back cover
10
Hi-Rel
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HUGD-50 Series
Gaia Converter FC97-027.01/06 Revision H
©
4
Go
+Vo
GI
VI
MGDM-series
Go
+Vo
GI
VI
MGDM-series
Go
+Vo
GI
VI
MGDM-series
Vcl
3
HUGD50
Go
+Vo
GI
CC
5
61
4
Vc 7
Vth
2
Vcl
PF
VI
CD
Rth** Rcl
Power fail signal
Capacitor charged signal
Capacitor discharged signal
On/Off
3
PGDS50
Go
+Vo
GI
VI
5
6
2
1
4
Vimes
R* C*
On/Off
+ Input
- Input
EMI input filter
L2
LMC1
C5
C1
C2
C3
L1
C4
R1 C6
C7
To help transitionning the system in the different operating
mode, GAÏA Converter recommends the use of a transi-
tion capacitor. This capacitor is used to maintain output
voltage during the HUGD-50 commutation from input line
to hold up capacitor. A 100µF electrolytic capacitor is
enough for a 50W load, and this value can be reduced for
lower loads.
The table below gives the minimum required values versus
output power :
The «power fail» output signal is activated when the vol-
tage drops below the power fail voltage threshold. the PF
signal is an open collector output active low.
The «capacitor charged» signal is actived when the vol-
tage at the capacitor pins reaches 34 VDC corresponding
to an energy stored of about 90% of it’s full charge.
The CC signal is an open collector output actived low.
The «capacitor discharged» signal is activated when the
voltage at the capacitor pins reaches 16.3 VDC (or 9.8
VDC) corresponding to a remaining energy of about 20%
of it’s full charge.
The CD signal is an open collector output active low.
10-9 Typical Schematics
This typical application schematics includes an EMI filter, a PGDS-50 pre-regulator, the hold-up module and an assembly of
standard DC/DC converters. Additionnal details are given in the EMI filters application notes and PGDS-50 datasheet.
10-8 Transition Capacitor10-7 Capacitor Discharged Signal : CD
10-6 Capacitor Charged Signal : CC10-5 Power Fail Signal : PF
Output power (W)
Capacitance value (µF)
10 20 30 40 50
22 47 68 82 100
Note * : Due to possible oscillations caused by surges or fast transients at the input voltage level, it is recommended to implement a RC filter on the VIMES signal; several
implementations as shown in the above figure can be tested to optimize the design. Typical values for the resistor R is 470 Ohm and for for the capacitance C is 1µF.
Note ** : When used in conjunction with PGDS-50 series, the resistance Rth of HUGD module has to be left unconnected.
10- Application Notes (continued)
For locations, phone, fax, E-Mail see back cover
11
Hi-Rel
Grade
HUGD-50 Series
Gaia Converter FC97-027.01/06 Revision H
©
4
10-10 Timming Diagram
The following diagram describes the HUGD-50 output signals through the different operation modes :
• Input voltage (Vi)
• Output voltage to DC/DC converter (Vo)
• Power Fail signal (PF)
• Capacitor voltage (Vc)
• Capacitor charged signal (CC)
• Capacitor discharge signals (CD)
10- Application Notes (continued)
For locations, phone, fax, E-Mail see back cover
12
Hi-Rel
Grade
HUGD-50 Series
Gaia Converter FC97-027.01/06 Revision H
©
4
11- Dimensions
Dimension are given in mm (inches). Tolerance : +/- 0,2 mm (+/- 0.01 “) unless otherwise indicated.
Weight : 20 grams (0.7 Ozs) max.
12- Product Marking
Upper face : Company logo, location of manufacturing.
Side face : Module reference, option, date code : year and week of manufacturing.
13- Connections
Metallic case black anodized coating solder plated pinPin dimensions : O 0,73 mm (0.03 ”)
40
(1.58")
35,56
(1.40")
7,60
(0.30")
5 min
(0.20")
20,32
(0.80")
26
(1.03")
8
(0.32")
26,20
(1.03")
5,08
(0.20")
7,62
(0.30")
3 x 2,54
(3 x 0.10")
2,54 (0.10")
2,54
(0.10")
7,62
(0.30")
10,16
(0.40")
Bottom view
4
12 3
5
68 9
7 10
Pin HUGD-50
1+ Input (Vi)
2Power Fail Threshold (Vth)
3Voltage Current Level (Vcl)
4- Input (Gi)
5Common (Go)
6Output (Vo)
7Voltage Capacitor (Vc)
8Power Fail Signal (PF)
9Capacitor charged signal (CC)
10 Capacitor discharged signal (CD)
Information given in this datasheet is believed to be accurate and reliable. However, no responsibility is assumed for the consequence of its use nor for any infringement of patents or other rights of third parties which may result from its use.
These products are sold only according to GAIA Converter general conditions of sale, unless otherwise confirmed by writing. Specifications subject to change without notice.
Printed in France by GAIA Converter Gaia Converter FC97-027.01/06 Revision H. Graphisme : Philippe Clicq
Represented by :
For more detailed specifications and applications information, contact :
International Headquarters
Marketing and Sales department
GAÏA Converter - France
Address : B.P. 26 - 33186 LE HAILLAN - FRANCE
Tel. : + (33)-5-57-92-12-80
Fax : + (33)-5-57-92-12-89
North American Headquarters
GAÏA Converter Canada, Inc
Address : 6611 Thimens
ST-LAURENT, QUEBEC - CANADA H4S 1W2
Tel. : (514)-333-3169
Fax : (514)-333-4519